Contact removal tool for electrical connector contacts

ABSTRACT

A tool for removing, from an electrical connector assembly, electrical contacts that are not attached to a wire or have their wire receiving well filled with solder. The tool is proportioned to fit into the bore of an electrical connector insert within which the contact is mounted. Movement of the tool into the insert bore unlocks the contact while grabbing the outside of the contact to permit extraction of the contact from the insert bore.

United States Patent 1 [11] 3,802,049

Hennessey, Jr. Apr. 9, 1974 [5 CONTACT REMOVAL TOOL FOR 3.382.558 5/1968 Lutz et al 29/203 H ELECTRICAL CONNECTOR CONTACTS 3,46l.533 8/1969 Anhalt 29/203 H W I F. S'd [75] Inventor N v Hennessey Jr 1 my Primary Exammer-Thomas H. Eager Attorney, Agent, or Firm-Raymond J. Eifler [73] Assignee: The Bendix Corporation, Southfield, 1

Mich.

[57] ABSTRACT 22] Filed: Feb. 27, 1973 A tool for removing, from an electrical connector as- PP 336,308 sembly, electrical contacts that are not attached to a wire or have their wire receiving well filled with sol- 52 us. Cl. 29/203 H The tool is proportioned to fit into the bore an [51] hm C]. "05k 3/04 electrical connector insert within which the contact is 5 i l f Search 29/203 H, 203 R, 20 203 D mounted. Movement Of the I001 into the insert bore unlocks the contact while grabbing the outside of the [56] References Cited contact to permit extraction of the contact from the UNITED STATES PATENTS 1 1 3,110,093 11/1963 Johnson 29/203 H 14 Claims, 6 Drawing Figures CONTACT REMOVAL TOOLFOR ELECTRICAL CONNECTOR CONTACTS BACKGROUND OF THE INVENTION This invention relates to a contact removal tool for an electrical connector assembly. This invention is more particularly related to a tool for removing electrical contacts that do not have a wire attached thereto.

In U.S. Pat. No. 3,1 10,093 entitled Contact Extraction and Insertion Tools issued Nov. 12, 1963 to G. S. Johnson, there is disclosed a tubular tool for releasing removable contacts, the tool being of the type which slips over a wire attached to the contact which is moved axially around the contact to release the contact from its retaining clip. The wire which is attached to the contact is then pulled in an axial direction to remove the contact. However, such a tool is limited in applications to situations in which the tool can be slipped over the wire as it is'the wire that actually removes the contact from the connector assembly. Therefore, this type of tool is inadequate for removing electrical contacts that do not have a wire attached thereto. Attempts have been made to provide a contact removal tool that is inserted into the wire well at one end of the contact to remove the contact from the connector insert. This type of tool is also unsatisfactory as it cannot be used in instances where the wire which was attached to the contact has broken off. Therefore, the wire well is not empty and cannot receive the contact removal tool.

SUMMARY OF THE INVENTION This invention provides a tool for removing an electrical contact from an electrical connector in'the event the contact is mounted in the connector insert without the wire attached thereto or the wire has broken off at the junction between the incoming wire and the electrical contact.

The invention is a contact removal tool that includes a tubular member 40 having an end portion 45 that releases a contact retaining mechanism 31 and grasps theend portion 15 of a contact so that it may be withdrawn from a connector insert 20. The radially expandable endportion 45 of the tool 40 is swaged 44 and includes one or more axial slots 41 therein so that the end portion may be expanded radially. In an alternate embodiment of the invention, the contact receiving portion 45 of the tool includes one or more shoulders 46 that engage at least one groove 16 in the contact 10.

In one embodiment of the invention, the invention may be described as a tool for removing an electrical contact 10 mounted within a bore of an electrical connector insert 20 by one or more radially deflectable retaining members 31 that extend inwardly with respect to the axis of the bore to engage an oppositely facing annular shoulder 11 on the contact 10 to prevent movement of the contact 10 in the direction the contact shoulder 11 faces, the contact having an end portion 15 and an enlarged portion 14 forming a contact shoulder 11, the tool comprising a tubular member 40 made of rigid material having a forward contact receiving portion 45 and a rear portion, the forward contact receiving portion 45 having a plurality of axial slots 41 in the wall thereof to make a portion of the forward contact receiving portions 45 radially flexible, the forward contact receiving portion 45 further including a first entrance passage portion 43 to receive the end portion 15 of the contact 10 and a second diverging and then convergingpassage portion that in cludes the slots 41 and which provide a narrowing passage 49 in the forward contact receiving portion so that when the tool is aligned with the contact 10 and an axial force is applied to the tool in the direction of the contact 10, the tool moves axially until the end 43 of the forward portion 45 engages the contact shoulder 1 1- while disengaging the radially deflectable retaining members 31 and forcing the contact end portion 15 into pressure contact with the inner wall of the diverging portion 49 of the tubular member 40, whereby when the tool is moved in the opposite direction, the contact, held by the tubular member, is moved from the connector insert; a shaft 50 coaxially and slidably mounted within the tubular member 40, the shaft 50 having a plunger end 51 extending from one end of the tubular member 40 and a contact ejection end. 52 which is movable to eject a contact held within the tubular member 40 when the plunger end 51 is depressed into the tubular member 40; and means for biasing the plunger in the direction of the rear end of the tubular member 40.

Accordingly, it is an object of this invention to provide a contact removal tool that is capable of removing contacts that do not'have a wire attached thereto or a blocked wire receiving well in the contact itself.

It is another object of this invention to provide a tool for removing electrical contacts from a multipin electrical connector.

The above and other objects and features of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings and claims which form a part of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagrammatic view of a contact removal tool that incorporates the principles of this invention.

FIG. 2 is a partial cross-sectional view of a contact receiving portion of the tool shown in FIG. 1.

FIG. 3 illustrates the contact removal tool shown in FIG. 1 in position to remove a contact inthe connector insert.

FIG. 4 illustrates the contact removal tool, which incorporates additional features, in its contact removal position.

FIG. 5 illustrates an additional feature that may be incorporated into the removal tool.

FIG. 6 illustrates an additional feature of an electrical contact that cooperates with the feature illustrated in FIG. 5.

DETAILED DESCRIPTION OF THE DRAWINGS Referring now to the drawings, FIG. 1 illustrates a contactremoval tool that accomplishes the objects of this invention. The contact removal tool includes a generally tubular member 40; a shaft 50 coaxially and slidably mounted within the tubular member40; and a spring .60 for resiliently extending the shaft 50 from one end 47 of the tubular member 40.

The tubular member 40 may be made from metal or a rigid plastic so that the tubular member 40 can receive an axial force without deformation. The tubular member 40 includes a forward contact receiving portion 45 and a rear end 47. The forward portion 45 includes an entrance portion 43 of substantially uniform diameter and a swaged portion 44 that forms a second passage portion, the diameter of which diverges from the diameter of the end portion 43 and then converges.

Coaxially and slidably mounted within the tubular member 40 is a shaft 50. The shaft 50 includes a plunger end 51 that extends from one end 47 of the tubular member 40. The opposite end 52 of the shaft 50 terminates within the tubular member 40 in its normal position. The shaft may be sized to expand the swaged portion 44 of the tubular member 40 to release the annular shoulder (46, FIG. 4) that mates with a recess (16, FIG. 6) in contact 10.

Mounted around the shaft 50 is a spring 60 which is held captive within the tubular member 40 by the tubular member shoulders 46, 48 and the shaft shoulder 58. Pressing the plunger end 51 of the shaft 50 causes the spring 60 to compress. Releasing the plunger 51 allows the spring 60 to expand and return the plunger to its original position with the tubular member, i.e., abutting shoulder 47 of tubular member 40.

FIG. 2 is a partial cross-sectional diagram of one end of the tool shown in FIG. 1. To obtain a radially expandable end portion from a tubular material such as metal or hard plastic which is substantially rigid, a plurality of axial slots 41 are made in the swaged portion 44 of the tubular member 40. The slots 41 allow the swaged portion 44 of the tool to expand radially when a member, such as a contact having a diameter larger than the inside diameter of the narrowed portion 49 is inserted therein. A contact having a larger diameter than the inner diameter of the narrowed portion 49 of the member 40 will be in pressure contact with the inside walls of the narrowed portion 49 of the tubular member 40, and thecontact will be retained thereby until sufficient forces are applied to overcome the force exerted on the contact by the inside walls of the tubular member 40.

FIG. 3 illustrates a partial diagrammatic view of a contact 10 disposed in a connector insert with the removal tool in position to remove the contact 10 from the connector insert 20. Generally, the connector assembly includes a forward insert 20, a rear grommet 50 and a contact 10, which is retained in the forward insert 20 by a retention mechanism 30. The contact generally includes an enlarged portion 14 that defines a for wardly facing shoulder 12, a rearwardly facing shoulder 11 and an end portion 15 that includes a well or bore (not shown) for receiving an electrical conductor. The retention assembly 30 generally includes a plurality of inwardly extending retention figures 31 that engage the rearwardly facing shoulder 11 of the contact 10 to secure it in position in the forward insert 20. The inside passage of the tubular member 40 includes a diverging or narrowing passage portion 49 that is sized to be smaller than the outside diameter at the rear end portion 15 of the contact 10. The end portion of the tubular member 40 that enters the insert and grommet 50 is sized to pass through and into the passages 55 and of the sealing grommet 15 and forward insert 20 respectively. Because of the variable diameter of the narrowing passage portion 49 of the tool 40, contacts having variable sized end portion 15 may be grasped and removed.

FIG. 4 illustrates the contact removal tool inserted in the contact removal position. In this figure, tubular member 40 is inserted into the insert 20 until it engages the shoulder 11 of the contact 10. In this position, the retention members 31 that extend into the bore are defiected out of engagement with the contact shoulder l 1 allowing the contact to be removed. The contact is generally held or grasped by the tubular member 40 by the pressure exerted between the surface of the rear end portion 15 of the contact 10 against the inside narrowing wall portion 49 of the tubular member 40. In this embodiment, to increase the grasping force of the tubular member 40 with a contact 10, the contact 10 is designed with one or more recesses or grooves 16 that receive one or more annular ridges or shoulders that mate with the groove or recess 16 in the contact.

FIG. 5 is a partial cross-sectional view of one end portion of the tool 40 that illustrates the annular ridges or shoulders 46 on the inside wall 49 of the swaged portion 44 of the tubular member 40.

FIG. 6 illustrates an electrical contact 10 that includes an annular recess or groove 16 in the end portion 15 of the contact 10. The groove 16 mates with the ridges 46 on the inside wall 49 of the tubular member 40.

OPERATION Referring now to the drawings, particularly FIG. 3, the removal tool operates as follows: The tubular member 40 is aligned with the axis of the contact 10 and inserted into the insert 20 by application of an axial force in the direction of the arrows. Once the tubular member 40 is inserted into the insert 20, the retention members 31 are deflected in a manner shown in FIG. 4. In this position, the contact may now be removed by the application of an axial force in the opposite direction of the arrow shown in FIG. 3. To grasp the contact 10 the inside wall 49 of the tubular member 40 is in pressure contact with the conductor receiving end 15 of the contact 10. To increase the pressure between the contact and the tubular member, a plurality of annular ridges or shoulders (46, FIG. 5 and 6) may be designed into the narrowing portion 49 of the tubular member 40. If a positive latch is desired, the contact 10 may be designed with a groove or recess 16 in the rear end portion 15, as shown in FIGS. 4 and 6, so that the shoulders or recesses 46 may mate with the ridges 46 to provide for more secure grasping of the contact 10 during withdrawal. Once the contact is withdrawn from the connector assembly, it is still retained by the forward end portion 45 of the tubular member 40. Referring now to FIG. 1, it can be seen that depression of the plunger 51 of shaft 50 will cause the opposite end 52 of the shaft 50 to move to the forward end 43 of the tubular member 40. This forward movement of the forward end 52 of the shaft 51 ejects the contact from the tubular member 40.

While a preferred embodiment of the invention has been disclosed, it will be apparent to those skilled in the art that changes may be made to the invention as set forth in the appended claims and, in some instances, certain features of the invention may be used to advantage without corresponding use of other features. Accordingly, it is intended that the illustrative and descriptive materials herein be used to illustrate the principles of the invention and not to limit the scope thereof.

Having thus described the invention, what is claimed is: 1. A tool for removing an electrical contact mounted within a bore of an electrical connector insert by one or more radially deflectable retaining members that extend inwardly with respect to the axis of said bore to engage an oppositely facing annular shoulder on said contact and prevent movement of said contact in the direction said contact shoulder faces, said contact having an end portion and an enlarged portion forming said contact shoulder, said tool comprising:

a tubular member made of rigid material and having a forward contact receiving portion and a rear portion, said forward contact receiving portion having a plurality of axial slots in the wall thereof to make a portion of said forward contact receiving portion radially flexible, said forward contact receiving portion further including a first entrance passage portion to receive said end portion of said contact and asecond diverging and then converging passage portion that includes said slots which provides a narrowing passage in the forward contact receiving portion so that when said tool is aligned with said contact and an axial force is applied to said tool in the direction of said contact, said tool moves axially until the end of said forward portion engages said contact shoulder while disengaging said radially deflectable retaining members and forcing said contact end portion into pressure contact with the inner wall of said diverging portion of said tool, whereby when said tool is moved in the opposite direction, said contact, held by said tool, is removed from said connector insert.

2. The tool as recited in claim 1 wherein said diverging passage portion of said tubular member includes at least one annular ridge.

3. The combination recited in claim 2 wherein said contact end portion includes means for receiving at least one of said ridges in saidtool whereby the axial force to separate said tool from said contact is increased over that provided by a tool without said ridge and a contact without said ridge receiving means.

4. The tool as recited in claim 1 including a contact release assembly comprising: a

a shaft coaxially and slidably mounted within said tubular member, said shaft having a plunger end extending from said rear end of said tubular member and a forward contact ejection end which is movable to eject a contact held within said tubular member when said plunger end is depressed.

5. The tool as recited in claim 4 including means for biasing said plunger in the direction of said rear end of said tubular member.

6. The tool as recited in claim 5 wherein said biasing means includes a spring captivated within said tool.

7. The tool as recited in claim 2 including a contact release assembly comprising:

a shaft coaxially and slidably mounted within said tubular too], said shaft having a plunger end extending from said rear end of said tool and a forward contact ejection end which is movable to eject a contact held within said tubular member when said plunger end is depressed.

8. The tool as recited in claim 7 including means for biasing said plunger into an extended position that allows a contact to be inserted into said forward end of said tool.

9. The tool as recited in claim 8 wherein said biasing means includes a spring captivated] within'said tool.

10. A tool for removing an electrical contact mounted within a bore of an electrical connector insert by one or more radially deflectable retaining members that extend inwardly with respect to the axis of said bore to engage an oppositely facing annular shoulder on said contact and prevent movement of said contact in the direction said contact shoulder faces, said contact having an end portion and an enlarged portion forming said contact shoulder, said tool comprising:

a tubular member having a forward contact receiving portion and a rear portion, said forward contact receiving portion having a plurality of axial slots in the wall thereof to make said forward contact receiving portion radially flexible, said forward contact receiving portion further including a first entrance passage portion to receive said end portion of said contact and a second diverging passage portion from said end portion that includes said slots and which provides a narrowing passage in the forward contact receiving portion that is radially expandable so that when said tool is aligned with said contact and an axial force is applied to said tool in the direction of said contact, said tool moves axially until the end of said forward portion engages said contact shoulder while disengaging said radially deflectable retaining members and forcing said contact end portion into pressure contact with the inner wall of said diverging portion of said tool, whereby when said tool is moved in the opposite direction, said contact, held by said tool, is removed from said connector insert; and

a shaft coaxially and slidably mounted within said tubular tool, said shaft having a plunger end extending from said rear end of said tool and a forward contact ejection end which ejects a contact held within said tool when said plunger end is depressed.

11. The tool as recited in claim 10 including means for biasing said plunger end into an extended position that allows a contact to be inserted into said forward end of said tool.

12. A tool for removing an electrical contact mounted within a bore of an electrical connector insert by one or more radially deflectable retaining shoulders that extend inwardly with respect to the axis of said bore to engage an oppositely facing annular shoulder on said contact and prevent movement of said contact in the direction said contact shoulder faces, said contact having an end portion, an enlarged portion forming said contact shoulder, and at least one groove in the end portion of said contact, said tool comprising:

a tubular member having a forward contact receiving portion and a rear portion, said forward contact receiving portion including a first entrance passage portion to receive said end portion of said contact and a second passage portion diverging from said end portion which provides a narrowing passage in the forward contact receiving portion that further includes at least one annular shoulder thereon adapted to mate with the groove in said contact when said contact end portion is inserted into said tool, whereby the axial forceto separate said tool from said contact is increased over that provided by a tool without said shoulder and a contact withopposite direction, said contact, held by said tool, is removed from said connector insert. 13. The tool as recited in claim 12 wherein said second diverging passage portion is radially expandable. 14. The tool as recited in claim 13 wherein said second passage portion includes a plurality of axial slots in the wall thereof. 

1. A tool for removing an electrical contact mounted within a bore of an electrical connector insert by one or more radially deflectable retaining members that extend inwardly with respect to the axis of said bore to engage an oppositely facing annular shoulder on said contact and prevent movement of said contact in the direction said contact shoulder faces, said contact having an end portion and an enlarged portion forming said contact shoulder, said tool comprising: a tubular member made of rigid material and having a forward contact receiving portion and a rear portion, said forward contact receiving portion having a plurality of axial slots in the wall thereof to make a portion of said forward contact receiving portion radially flexible, said forward contact receiving portion further including a first entrance passage portion to receive said end portion of said contact and a second diverging and then converging passage portion that includes said slots which provides a narrowing passage in the forward contact receiving portion so that when said tool is aligned with said contact and an axial force is applied to said tool in the direction of said contact, said tool moves axially until the end of said forward portion engages said contact shoulder while disengaging said radially deflectable retaining members and forcing said contact end portion into pressure contact with the inner wall of said diverging portion of said tool, whereby when said tool is moved in the opposite direction, said contact, held by said tool, is removed from said connector insert.
 2. The tool as recited in claim 1 wherein said diverging passage portion of said tubular member includes at least one annular ridge.
 3. The combination recited in claim 2 wherein said contact end portion includes means for receiving at least one of said ridges in said tool whEreby the axial force to separate said tool from said contact is increased over that provided by a tool without said ridge and a contact without said ridge receiving means.
 4. The tool as recited in claim 1 including a contact release assembly comprising: a shaft coaxially and slidably mounted within said tubular member, said shaft having a plunger end extending from said rear end of said tubular member and a forward contact ejection end which is movable to eject a contact held within said tubular member when said plunger end is depressed.
 5. The tool as recited in claim 4 including means for biasing said plunger in the direction of said rear end of said tubular member.
 6. The tool as recited in claim 5 wherein said biasing means includes a spring captivated within said tool.
 7. The tool as recited in claim 2 including a contact release assembly comprising: a shaft coaxially and slidably mounted within said tubular tool, said shaft having a plunger end extending from said rear end of said tool and a forward contact ejection end which is movable to eject a contact held within said tubular member when said plunger end is depressed.
 8. The tool as recited in claim 7 including means for biasing said plunger into an extended position that allows a contact to be inserted into said forward end of said tool.
 9. The tool as recited in claim 8 wherein said biasing means includes a spring captivated within said tool.
 10. A tool for removing an electrical contact mounted within a bore of an electrical connector insert by one or more radially deflectable retaining members that extend inwardly with respect to the axis of said bore to engage an oppositely facing annular shoulder on said contact and prevent movement of said contact in the direction said contact shoulder faces, said contact having an end portion and an enlarged portion forming said contact shoulder, said tool comprising: a tubular member having a forward contact receiving portion and a rear portion, said forward contact receiving portion having a plurality of axial slots in the wall thereof to make said forward contact receiving portion radially flexible, said forward contact receiving portion further including a first entrance passage portion to receive said end portion of said contact and a second diverging passage portion from said end portion that includes said slots and which provides a narrowing passage in the forward contact receiving portion that is radially expandable so that when said tool is aligned with said contact and an axial force is applied to said tool in the direction of said contact, said tool moves axially until the end of said forward portion engages said contact shoulder while disengaging said radially deflectable retaining members and forcing said contact end portion into pressure contact with the inner wall of said diverging portion of said tool, whereby when said tool is moved in the opposite direction, said contact, held by said tool, is removed from said connector insert; and a shaft coaxially and slidably mounted within said tubular tool, said shaft having a plunger end extending from said rear end of said tool and a forward contact ejection end which ejects a contact held within said tool when said plunger end is depressed.
 11. The tool as recited in claim 10 including means for biasing said plunger end into an extended position that allows a contact to be inserted into said forward end of said tool.
 12. A tool for removing an electrical contact mounted within a bore of an electrical connector insert by one or more radially deflectable retaining shoulders that extend inwardly with respect to the axis of said bore to engage an oppositely facing annular shoulder on said contact and prevent movement of said contact in the direction said contact shoulder faces, said contact having an end portion, an enlarged portion forming said contact shoulder, and at least one groove in the end portion of said contact, said tool comprising: a tubular member having a foRward contact receiving portion and a rear portion, said forward contact receiving portion including a first entrance passage portion to receive said end portion of said contact and a second passage portion diverging from said end portion which provides a narrowing passage in the forward contact receiving portion that further includes at least one annular shoulder thereon adapted to mate with the groove in said contact when said contact end portion is inserted into said tool, whereby the axial force to separate said tool from said contact is increased over that provided by a tool without said shoulder and a contact without said groove so that when said tool is aligned with said contact and an axial force is applied to said tool in the direction of said contact, said tool moves axially until the end of the tool engages said contact shoulder while disengaging said radially deflectable retaining shoulders and engaging said annular shoulder on said tool with said groove in said contact, whereby when said tool is moved in the opposite direction, said contact, held by said tool, is removed from said connector insert.
 13. The tool as recited in claim 12 wherein said second diverging passage portion is radially expandable.
 14. The tool as recited in claim 13 wherein said second passage portion includes a plurality of axial slots in the wall thereof. 